Method and system of dehydrating a feed stream processed in a distillation tower

ABSTRACT

The present disclosure provides a method of dehydrating a feed stream processed in a distillation tower. The method may include (a) introducing a feed stream comprising a first contaminant stream into a distillation tower; (b) forming a solid from the feed stream in a controlled freeze zone section of the distillation tower; (c) feeding a second contaminant stream into the feed stream outside the distillation tower; and (d) removing water from the feed stream with a second contaminant stream by feeding the second contaminant stream.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. patent application No. 61/912,970 filed Dec. 6, 2013 entitled METHOD AND SYSTEM OF DEHYDRATING A FEED STREAM PROCESSED IN A DISTILLATION TOWER, the entirety of which is incorporated by reference herein.

This application is related to but does not claim priority to U.S. Provisional patent application numbers: 61/912,957 filed Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SPRAY ASSEMBLY; 62/044,770 filed Sep. 2, 2014 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SPRAY ASSEMBLY; 61/912,959 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM OF MAINTAINING A LIQUID LEVEL IN A DISTILLATION TOWER; 61/912,964 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING A FEED STREAM USING RADIATION DETECTORS; 61/912,975 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM FOR SEPARATING A FEED STREAM WITH A FEED STREAM DISTRIBUTION MECHANISM; 61/912,978 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM FOR PREVENTING ACCUMULATION OF SOLIDS IN A DISTILLATION TOWER; 61/912,983 filed on Dec. 6, 2013 entitled METHOD OF REMOVING SOLIDS BY MODIFYING A LIQUID LEVEL IN A DISTILLATION TOWER; 61/912,984 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM OF MODIFYING A LIQUID LEVEL DURING START-UP OPERATIONS; 61/912,986 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A HEATING MECHANISM TO DESTABILIZE AND/OR PREVENT ADHESION OF SOLIDS; 61/912,987 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SURFACE TREATMENT MECHANISM.

BACKGROUND

1. Fields of Disclosure

The disclosure relates generally to the field of fluid separation. More specifically, the disclosure relates to the cryogenic separation of contaminants, such as acid gas, from a hydrocarbon.

2. Description of Related Art

This section is intended to introduce various aspects of the art, which may be associated with the present disclosure. This discussion is intended to provide a framework to facilitate a better understanding of particular aspects of the present disclosure. Accordingly, it should be understood that this section should be read in this light, and not necessarily as admissions of prior art.

The production of natural gas hydrocarbons, such as methane and ethane, from a reservoir oftentimes carries with it the incidental production of non-hydrocarbon gases. Such gases include contaminants, such as at least one of carbon dioxide (“CO₂”), hydrogen sulfide (“H₂S”), carbonyl sulfide, carbon disulfide and various mercaptans. When a feed stream being produced from a reservoir includes these contaminants mixed with hydrocarbons, the stream is oftentimes referred to as “sour gas.”

Many natural gas reservoirs have relatively low percentages of hydrocarbons and relatively high percentages of contaminants. Contaminants may act as a diluent and lower the heat content of hydrocarbons. Some contaminants, like sulfur-bearing compounds, are noxious and may even be lethal. Additionally, in the presence of water some contaminants can become quite corrosive.

It is desirable to remove contaminants from a stream containing hydrocarbons to produce sweet and concentrated hydrocarbons. Specifications for pipeline quality natural gas typically call for a maximum of 2-4% CO₂ and ¼grain H₂S per 100 scf (4 ppmv) or 5 mg/Nm3 H₂S. Specifications for lower temperature processes such as natural gas liquefaction plants or nitrogen rejection units typically require less than 50 ppm CO₂.

Separation by distillation of some mixtures can be relatively simple and, as such, is widely used in the natural gas industry. However, distillation of mixtures of natural gas hydrocarbons, primarily methane, and one of the most common contaminants in natural gas, carbon dioxide, can present significant difficulties. Conventional distillation principles and conventional distillation equipment are predicated on the presence of only vapor and liquid phases throughout the distillation tower. The separation of CO₂ from methane by distillation involves temperature and pressure conditions that result in solidification of CO₂ if a pipeline or better quality hydrocarbon product is desired. The required temperatures are cold temperatures typically referred to as cryogenic temperatures.

Certain cryogenic distillations can overcome the above mentioned difficulties. These cryogenic distillations provide the appropriate mechanism to handle the formation and subsequent melting of solids during the separation of solid-forming contaminants from hydrocarbons. The formation of solid contaminants in equilibrium with vapor-liquid mixtures of hydrocarbons and contaminants at particular conditions of temperature and pressure takes place in a controlled freeze zone section.

Certain cryogenic distillations can overcome the above mentioned difficulties. These cryogenic distillations provide the appropriate mechanism to handle the formation and subsequent melting of solids during the separation of solid forming contaminants from hydrocarbons. The formation of solid contaminants in equilibrium with vapor-liquid mixtures of the hydrocarbons and contaminants at particular conditions of temperature and pressure takes place in a controlled freeze zone section.

For cryogenic distillation and the controlled freeze zone section to work properly, the feed stream entering the distillation tower must be sufficiently dehydrated. Most often the feed stream for cryogenic distillation is dehydrated in a dehydration unit comprising a molecular sieve. The dehydration unit removes water from the feed stream to prevent the water from later presenting a problem in the distillation tower. Water can present a problem by forming a separate water phase (i.e., ice and/or hydrate) that negatively affects the distillation process in the distillation tower.

Although the molecular sieve can sufficiently dehydrate the feed stream, molecular sieves can be expensive, be heavy, and require a lot of energy. Thus, there is a desire to use a dehydration unit that is less expensive, lighter and/or does not require as much energy as a molecular sieve. Some to all of these requirements could be met if the amount of carbon dioxide in the feed stream entering the distillation tower is greater than 25% as liquid carbon dioxide has a significant water moisture carrying capacity that can be used advantageously to reduce dehydration requirements. But many feed streams do not contain this much carbon dioxide when the feed stream enters the distillation tower.

While there are other dehydration units or systems, such as glycol-based units, that can dehydrate the feed stream and use less energy than a molecular sieve, glycol-based units alone cannot dehydrate the feed stream enough to prevent the formation of a separate water phase without the help of the moisture carrying capacity of sufficient carbon dioxide in the feed stream. Consequently, separate water phases may result when the feed stream entering the distillation tower has less than 25% carbon dioxide and the dehydration unit comprises a glycol-based dehydration unit. As a result, the distillation tower cannot successfully operate to separate contaminants from methane.

A need, therefore, exists for improved technology, including technology that may address one or more of the above described disadvantages. Specifically, a need exists for a method and system that dehydrates a feed stream processed in a distillation tower.

SUMMARY

The present disclosure provides a device and method for separating contaminants from hydrocarbons, among other things.

A method of dehydrating a feed stream processed in a distillation tower may comprise (a) introducing a feed stream comprising a first contaminant stream into a distillation tower; (b) forming a solid from the feed stream in a controlled freeze zone section of the distillation tower; (c) feeding a second contaminant stream into the feed stream outside of the distillation tower; and (d) removing water from the feed stream with a second contaminant stream by feeding the second contaminant stream.

A method of producing hydrocarbons may comprise (a) introducing a feed stream comprising a first contaminant stream and a hydrocarbon into a distillation tower; (b) forming a solid from the feed stream in a controlled freeze zone section of the distillation tower; (c) feeding a second contaminant stream into the feed stream outside of the distillation tower; (d) removing water from the feed stream with a second contaminant stream by feeding the second contaminant stream; and (e) producing the hydrocarbon from the distillation tower after forming the solid.

A system of dehydrating a feed stream processed in a distillation tower may comprise a dehydration unit that dehydrates a feed stream comprising a first contaminant stream; a feed stream inlet channel extending from the dehydration unit; a distillation tower comprising a controlled freeze zone section constructed and arranged to form a solid from the feed stream; and at least one of: (a) a second contaminant storage tank holding a second contaminant stream and connected to the feed stream inlet channel, and (b) a distillation tower outlet channel extending from the distillation tower to the feed stream inlet channel and configured to transport the second contaminant stream. The feed stream inlet channel extends to the distillation tower and is constructed and arranged to transport the first contaminant stream and the second contaminant stream.

The foregoing has broadly outlined the features of the present disclosure in order that the detailed description that follows may be better understood. Additional features will also be described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the disclosure will become apparent from the following description, appending claims and the accompanying drawings, which are briefly described below.

FIG. 1 is a schematic diagram of a tower with sections within a single vessel.

FIG. 2 is a schematic diagram of a tower with sections within multiple vessels.

FIG. 3 is a schematic diagram of a tower with sections within a single vessel.

FIG. 4 is a schematic diagram of a tower with sections within multiple vessels.

FIG. 5 is a schematic diagram of system for increasing the carbon dioxide in a feed stream.

FIG. 6 is a flowchart of a method within the scope of the present disclosure.

It should be noted that the figures are merely examples and no limitations on the scope of the present disclosure are intended thereby. Further, the figures are generally not drawn to scale, but are drafted for purposes of convenience and clarity in illustrating various aspects of the disclosure.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the features illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications, and any further applications of the principles of the disclosure as described herein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. It will be apparent to those skilled in the relevant art that some features that are not relevant to the present disclosure may not be shown in the drawings for the sake of clarity.

As referenced in this application, the terms “stream,” “gas stream,” “vapor stream,” and “liquid stream” refer to different stages of a feed stream as the feed stream is processed in a distillation tower that separates methane, the primary hydrocarbon in natural gas, from contaminants. Although the phrases “gas stream,” “vapor stream,” and “liquid stream,” refer to situations where a gas, vapor, and liquid is mainly present in the stream, respectively, there may be other phases also present within the stream. For example, a gas may also be present in a “liquid stream.” In some instances, the terms “gas stream” and “vapor stream” may be used interchangeably.

The disclosure relates to a system and method for dehydrating a feed stream processed in a distillation tower. To dehydrate the feed stream, an amount of second contaminant (e.g. liquid carbon dioxide) in the feed stream, which will enter the distillation tower, may be increased before the feed stream enters the distillation tower. FIGS. 1-6 of the disclosure display various aspects of the system and method.

The system and method of dehydrating a feed stream may comprise a distillation tower 104, 204 (FIGS. 1-2). The distillation tower 104, 204 may separate the contaminants in the feed stream from the methane in the feed stream.

The distillation tower 104, 204 may be separated into three functional sections: a lower section 106, a middle controlled freeze zone section 108 and an upper section 110. The distillation tower 104, 204 may incorporate three functional sections when the upper section 110 is needed and/or desired.

The distillation tower 104, 204 may incorporate only two functional sections when the upper section 110 is not needed and/or desired. When the distillation tower does not include an upper section 110, a portion of vapor leaving the middle controlled freeze zone section 108 may be condensed in a condenser 122 and returned as a liquid stream via a spray assembly 129. Moreover, lines 18 and 20 may be eliminated, elements 124 and 126 may be one and the same, and elements 150 and 128 may be one and the same. The stream in line 14, now taking the vapors leaving the middle controlled freeze section 108, directs these vapors to the condenser 122.

The lower section 106 may also be referred to as a stripper section. The middle controlled freeze zone section 108 may also be referred to as a controlled freeze zone section. The upper section 110 may also be referred to as a rectifier section.

The sections of the distillation tower 104 may be housed within a single vessel (FIGS. 1 and 3). For example, the lower section 106, the middle controlled freeze zone section 108, and the upper section 110 may be housed within a single vessel 164.

The sections of the distillation tower 204 may be housed within a plurality of vessels to form a split-tower configuration (FIGS. 2 and 4). Each of the vessels may be separate from the other vessels. Piping and/or another suitable mechanism may connect one vessel to another vessel. In this instance, the lower section 106, middle controlled freeze zone section 108 and upper section 110 may be housed within two or more vessels. For example, as shown in FIGS. 2 and 4, the upper section 110 may be housed within a single vessel 254 and the lower and middle controlled freeze zone sections 106, 108 may be housed within a single vessel 264. When this is the case, a liquid stream exiting the upper section 110, may exit through a liquid outlet bottom 260. The liquid outlet bottom 260 is at the bottom of the upper section 110. Although not shown, each of the sections may be housed within its own separate vessel, or one or more section may be housed within separate vessels, or the upper and middle controlled freeze zone sections may be housed within a single vessel and the lower section may be housed within a single vessel, etc. When sections of the distillation tower are housed within vessels, the vessels may be side-by-side along a horizontal line and/or above each other along a vertical line.

The split-tower configuration may be beneficial in situations where the height of the distillation tower, motion considerations, and/or transportation issues, such as for remote locations, need to be considered. This split-tower configuration allows for the independent operation of one or more sections. For example, when the upper section is housed within a single vessel and the lower and middle controlled freeze zone sections are housed within a single vessel, independent generation of reflux liquids using a substantially contaminant-free, largely hydrocarbon stream from a packed gas pipeline or an adjacent hydrocarbon line, may occur in the upper section. And the reflux may be used to cool the upper section, establish an appropriate temperature profile in the upper section, and/or build up liquid inventory at the bottom of the upper section to serve as an initial source of spray liquids for the middle controlled freeze zone section. Moreover, the middle controlled freeze zone and lower sections may be independently prepared by chilling the feed stream, feeding it to the optimal location be that in the lower section or in the middle controlled freeze zone section, generating liquids for the lower and the middle controlled freeze zone sections, and disposing the vapors off the middle controlled freeze zone section while they are off specification with too high a contaminant content. Also, liquid from the upper section may be intermittently or continuously sprayed, building up liquid level in the bottom of the middle controlled freeze zone section and bringing the contaminant content in the middle controlled freeze zone section down and near steady state level so that the two vessels may be connected to send the vapor stream from the middle controlled freeze zone section to the upper section, continuously spraying liquid from the bottom of the upper section into the middle controlled freeze zone section and stabilizing operations into steady state conditions. The split tower configuration may utilize a sump of the upper section as a liquid receiver for the pump 128, therefore obviating the need for a liquid receiver 126 in FIGS. 1 and 3.

The system may also include a heat exchanger 100 (FIGS. 1-4). The feed stream 10 may enter the heat exchanger 100 before entering the distillation tower 104, 204. The feed stream 10 may be cooled within the heat exchanger 100. The heat exchanger 100 helps drop the temperature of the feed stream 10 to a level suitable for introduction into the distillation tower 104, 204.

The system may include an expander device 102 (FIGS. 1-4). The feed stream 10 may enter the expander device 102 before entering the distillation tower 104, 204. The feed stream 10 may be expanded in the expander device 102 after exiting the heat exchanger 100. The expander device 102 helps drop the temperature of the feed stream 10 to a level suitable for introduction into the distillation tower 104, 204. The expander device 102 may be any suitable device, such as a valve. If the expander device 102 is a valve, the valve may be any suitable valve that may aid in cooling the feed stream 10 before it enters the distillation tower 104, 204. For example, the valve 102 may comprise a Joule-Thompson (J-T) valve.

The system may include a feed separator 103 (FIGS. 3-4). The feed stream may enter the feed separator before entering the distillation tower 104, 204. The feed separator may separate a feed stream having a mixed liquid and vapor stream into a liquid stream and a vapor stream. Lines 12 may extend from the feed separator to the distillation tower 104, 204. One of the lines 12 may receive the vapor stream from the feed separator. Another one of the lines 12 may receive the liquid stream from the feed separator. Each of the lines 12 may extend to the same and/or different sections (i.e. middle controlled freeze zone, and lower sections) of the distillation tower 104, 204. The expander device 102 may or may not be downstream of the feed separator 103. The expander device 102 may comprise a plurality of expander devices 102 such that each line 12 has an expander device 102.

The system includes a dehydration unit 261 that dehydrates the feed stream 10 (FIGS. 1-5). The dehydration unit 261 dehydrates the feed stream to a dew point sufficiently low to ensure a separate water phase does not form at any point downstream during the rest of the process. The dehydration unit 261 dehydrates the feed stream before the feed stream enters the distillation tower 104, 204. The feed stream may comprise a contaminant and the contaminant in the feed stream 10 may comprise a first contaminant stream.

The dehydration unit 261 removes water from the feed stream 10 to prevent water from later presenting a problem in the heat exchanger 100, expander device 102, feed separator 103 or distillation tower 104, 204. The water can present a problem by forming a separate water phase (i.e., ice and/or hydrate) that plugs lines, equipment or negatively affects the distillation process. When removing water from the feed stream, the dehydration unit 261 may dehydrate the feed stream to a dew point sufficiently low to ensure a separate water phase will not form at any point downstream during the rest of the process.

The system may include a feed stream inlet channel 12 (FIGS. 1-5) that extends to the dehydration unit 261. The feed stream inlet channel 12 may also extend to the distillation tower 104, 204. The feed stream inlet channel 12 may extend to the lower section 106 or the middle controlled freeze zone section 108 of the distillation tower 104, 204. For example, the feed stream inlet channel 12 may extend to the lower section 106 such that the feed stream 10 may enter the lower section 106 of the distillation tower 104, 204 (FIGS. 1-4). The feed stream inlet channel 12 may directly or indirectly extend to the lower section 106 or the middle controlled freeze zone section 108. The feed stream inlet channel 12 may extend to an outer surface of the distillation tower 104, 204 before entering the distillation tower.

If the system includes the feed separator 103 (FIGS. 3-4), the line 12 may comprise a plurality of lines 12. Each line may be the same line as one of the lines that extends from the feed separator to a specific portion of the distillation tower 104, 204.

The feed stream inlet channel 12 may be constructed and arranged to transport the feed stream. The feed stream inlet channel 12 transports the feed stream from a feed stream location 269 (FIG. 5) to the distillation tower 104, 204. In other words, the feed stream inlet channel 12 introduces the feed stream 10 into the distillation tower 104, 204, 301 (FIG. 6). The feed stream location 269 may be any suitable location, such as a gas reservoir. The feed stream inlet channel 12 may also be referred to as a line.

The feed stream 10 from the feed stream location 269 may have a low concentration of a first contaminant. For example, the feed stream 10 from the feed stream location 269 may comprise less than 25% of the first contaminant. When the feed stream 10 comprises less than 25% of the first contaminant, a total amount of contaminant in the feed stream may need to be increased. By increasing the total amount of contaminant in the feed stream, water in the feed stream can be prevented from forming any undesired phases in the distillation tower 104, 204.

To prevent the water in the feed stream from forming any undesired phases in the distillation tower 104, 204, the system may include at least one of (a) a second contaminant storage tank 264 and (b) a distillation tower outlet channel 262, 263, 268 that extends from the distillation tower 104, 204 (FIG. 5). While FIG. 5 shows both a second contaminant storage tank 264, a storage tank channel 265, 266, 267 and a distillation tower outlet channel 262, 263, 268, the system may include, for example, only the second contaminant storage tank 264 and the storage tank channel 265, 266, 267, only the distillation tower outlet channel 262, 263 or the second contaminant storage tank 264, or the storage tank channel 265, 266, 267 and the distillation tower outlet channel 262, 263. Moreover, while FIG. 5 shows lines 263 and 266 as separate lines and lines 262 and 267 as separate lines, lines 263 and 266 may be the same line and/or lines 262 and 267 may be the same line.

The second contaminant storage tank 264 holds a second contaminant stream and connects to the feed stream inlet channel 12. The second contaminant storage tank 264 connects to the feed stream inlet channel 12 via storage tank channel 265, 266, 267. The storage tank channel 265, 266, 267 transports the second contaminant stream from the second contaminant storage tank 264 to the feed stream inlet channel 12. The second contaminant storage tank 264 is outside of the distillation tower 104, 204. The second contaminant storage tank 264 is separate and distinct from the distillation tower 104, 204.

The storage tank channel 265, 266, 267 connects to the feed stream inlet channel 12 at one or more locations. The storage tank channel 265, 266, 267 may transport the second contaminant stream from the second contaminant storage tank 264 to before the dehydration unit 261 via lines 265 and 266 of the storage tank channel 265, 266, 267. The storage tank channel 265, 266, 267 may transport the second contaminant stream from the second contaminant storage tank 264 to between the dehydration unit 261 and the heat exchanger 100 via lines 265 and 267 of the storage tank channel 265, 266, 267.

The distillation tower outlet channel 262, 263, 268 is constructed and arranged to transport the second contaminant stream. The distillation tower outlet channel 262, 263, 268 extends from a liquid outlet 160 of the lower section 106 (FIGS. 1-5) to the feed stream inlet channel 12. The distillation tower outlet channel 262, 263, 268 transports the second contaminant stream from the liquid outlet 160 to the feed stream inlet channel 12 (FIG. 5).

The distillation tower outlet channel 262, 263, 268 may transport the second contaminant stream to one or more locations along the feed stream inlet channel 12. The distillation tower outlet channel 262, 263, 268 may transport the second contaminant stream from the lower section 108 to before the dehydration unit 261 via lines 263 and 268 of the distillation tower outlet channel 262, 263, 268. The distillation tower outlet channel 262, 263, 268 may transport the second contaminant stream from the lower section 108 to between the dehydration unit 261 and the heat exchanger 100 via lines 262 and 268 of the distillation tower outlet channel 262, 263, 268. The second contaminant stream is transported in the distillation tower outlet channel 262, 263, 268. It may be more beneficial to transport the second contaminant stream to between the dehydration unit 261 and heat exchanger 100 than before the dehydration unit 261 to polish the feed stream to a lower water content. Polishing the feed stream to a lower water content helps prevent undesired water phases from forming in the distillation tower 104, 204. The feed stream may be polished to a lower water content by transporting the second contaminant stream to between the dehydration unit 261 and heat exchanger 100 because the second contaminant stream is more likely to have sufficient capacity to absorb residual water if the stream enters after the dehydration unit 261.

The second contaminant stream may comprise any suitable contaminant. For example, the second contaminant stream may be at least a portion of the first contaminant stream. Alternatively, the second contaminant stream may be one of a same type and a different type of contaminant from the second contaminant stream. If the first contaminant stream comprises carbon dioxide and the second contaminant stream is the same type of contaminant as the first contaminant stream, then the second contaminant stream also comprises carbon dioxide. If the second contaminant stream is transported by the distillation tower outlet channel 262, 263, 268, the second contaminant stream may comprise feed stream processed in the distillation tower 104, 204. Oftentimes, the stream exiting the distillation tower 104, 204 via liquid outlet 160, comprises more contaminant from the feed stream than of methane The feed stream exiting the tower may be referred to as an enriched contaminant bottom liquid stream, which is formed in the lower section 106 (FIG. 6).

When the feed stream is dehydrated, in part by using a second contaminant stream, before being processed in the distillation tower 104, 204, water is removed from the vapor phase of the feed stream, 304. Water is removed from the vapor phase of the feed stream by feeding the second contaminant stream into the feed stream outside of the distillation tower, 303 (FIG. 6). Specifically, the second contaminant stream is fed to the feed stream inlet channel 12. The second contaminant stream may be fed to the feed stream inlet channel 12 via the storage tank channel 265, 266, 267 and/or the distillation tower outlet channel 262, 263, 268. When the second contaminant stream is fed to the feed stream inlet channel 12 via the storage tank channel 265, 266, 267 the second contaminant stream is transported from the second contaminant storage tank 264. When the second contaminant stream is fed to the feed stream inlet channel 12 via the distillation tower outlet channel 262, 263, 268, the second contaminant stream is transported from the liquid outlet 160 of the lower section 106.

Once the second contaminant stream is fed to the feed stream, the total amount of contaminant in the feed stream comprises the first contaminant stream and the second contaminant stream. While the second contaminant stream may be fed to the feed stream any amount of times, the second contaminant stream is preferably fed to the feed stream until the total amount of contaminant in the feed stream transported through the feed stream inlet channel 12 is between about 25 to 35%, between 25 to 35% of the feed stream, or within a range that includes or is bounded by any of the preceding examples of total amount of contaminant Once the total amount of contaminant reaches this level, the dehydration unit 261 may be any suitable dehydration unit, such as a glycol-based unit or a molecular sieve. The dehydration unit 261 may be any suitable dehydration unit because the amount of contaminant in the feed stream being processed in the distillation tower 104, 204 is enough to sufficiently dehydrate the feed stream before it enters the distillation tower 104, 204 so as to prevent undesired water phases from forming.

The second contaminant stream may be fed to the feed stream continuously or intermittently. For example, the second contaminant stream may be intermittently or continuously fed to the feed stream from any combination or lack thereof of at least one of the lower section 106 and the second contaminant storage tank 264.

The second contaminant stream may be at least partially dehydrated prior to introducing it into the feed stream. The second contaminant stream may be withdrawn after contact with the feed stream. The second contaminant stream may be introduced into a lower section of the stripper. A third enriched contaminant stream may be generated from the first contaminant stream and/or from the second contaminant stream. This third contaminant stream may be more hygroscopic than the other contaminant streams (i.e., the first contaminant stream and/or the second contaminant stream). The third contaminant stream may be under-saturated with respect to water so that it will absorb water vapor from the feed stream when the third contaminant stream is placed in contact with the feed stream.

While the above paragraphs disclose increasing the total amount of contaminant in the feed stream until the total amount of contaminant is between about 25-35% of the feed stream, the total amount of contaminant in the feed stream could be increased to a higher amount. For example, the total amount of contaminant in the feed stream could be increased to above 25-35%.

The system may include a filtering unit (not shown). The feed stream 10 may enter the filtering unit before entering the distillation tower 104, 204. The filtering unit may remove undesirable contaminants from the feed stream before the feed stream enters the distillation tower 104, 204. Depending on what contaminants are to be removed, the filtering unit may be before or after the dehydration unit 261 and/or before or after the heat exchanger 100.

The lower section 106 is constructed and arranged to separate the feed stream 10 into an enriched contaminant bottom liquid stream (i.e., liquid stream) and a freezing zone vapor stream (i.e., vapor stream). The enriched contaminant liquids bottom stream is what exits the lower outlet 160 and at least part of this stream may be what is fed to the inlet channel 12 to increase the total amount of contaminant in the feed stream. The lower section 106 separates the feed stream at a temperature and pressure at which no solids form. The liquid stream may comprise a greater quantity of contaminants than of methane. The vapor stream may comprise a greater quantity of methane than of contaminants. In any case, the vapor stream is lighter than the liquid stream. As a result, the vapor stream rises from the lower section 106 and the liquid stream falls to the bottom of the lower section 106.

The lower section 106 may include and/or connect to equipment that separates the feed stream. The equipment may comprise any suitable equipment for separating methane from contaminants, such as one or more packed sections 181, or one or more distillation trays with perforations downcomers and weirs (FIGS. 1-4).

The equipment may include components that apply heat to the stream to form the vapor stream and the liquid stream. For example, the equipment may comprise a first reboiler 112 that applies heat to the stream. The first reboiler 112 may be located outside of the distillation tower 104, 204. The equipment may also comprise a second reboiler 172 that applies heat to the stream. The second reboiler 172 may be located outside of the distillation tower 104, 204. Line 117 may lead from the distillation tower to the second reboiler 172. Line 17 may lead from the second reboiler 172 to the distillation tower. Additional reboilers, set up similarly to the second reboiler described above, may also be used.

The first reboiler 112 may apply heat to the liquid stream that exits the lower section 106 through a liquid outlet 160 of the lower section 106. The liquid stream may travel from the liquid outlet 160 through line 28 to reach the first reboiler 112 (FIGS. 1-4). The amount of heat applied to the liquid stream by the first reboiler 112 can be increased to separate more methane from contaminants. The more heat applied by the reboiler 112 to the stream, the more methane separated from the liquid contaminants, though more contaminants will also be vaporized.

The first reboiler 112 may also apply heat to the stream within the distillation tower 104, 204. Specifically, the heat applied by the first reboiler 112 warms up the lower section 106. This heat travels up the lower section 106 and supplies heat to warm solids entering a melt tray assembly 139 (FIGS. 1-4) of the middle controlled freeze zone section 108 so that the solids form a liquid and/or slurry mix.

The second reboiler 172 applies heat to the stream within the lower section 106. This heat is applied closer to the middle controlled freeze zone section 108 than the heat applied by the first reboiler 112. As a result, the heat applied by the second reboiler 172 reaches the middle controlled freeze zone section 108 faster than the heat applied by the first reboiler 112. The second reboiler 172 may also help with energy integration.

The equipment may include a chimney assembly 135 (FIGS. 1-4). While falling to the bottom of the lower section 106, the liquid stream may encounter one or more of the chimney assemblies 135.

Each chimney assembly 135 includes a chimney tray 131 that collects the liquid stream within the lower section 106. The liquid stream that collects on the chimney tray 131 may be fed to the second reboiler 172. After the liquid stream is heated in the second reboiler 172, the stream may return to the middle controlled freeze zone section 106 to supply heat to the middle controlled freeze zone section 106 and/or the melt tray assembly 139. Unvaporized stream exiting the second reboiler 172 may be fed back to the distillation tower 104, 204 below the chimney tray 131. Vapor stream exiting the second reboiler 172 may be routed under or above the chimney tray 131 when the vapor stream enters the distillation tower 104, 204.

The chimney tray 131 may include one or more chimneys 137. The chimney 137 serves as a channel that the vapor stream in the lower section 106 traverses. The vapor stream travels through an opening in the chimney tray 131 at the bottom of the chimney 137 to the top of the chimney 137. The opening is closer to the bottom of the lower section 106 than it is to the bottom of the middle controlled freeze zone section 108. The top is closer to the bottom of the middle controlled freeze zone section 108 than it is to the bottom of the lower section 106.

Each chimney 137 has attached to it a chimney cap 133. The chimney cap 133 covers a chimney top opening 138 of the chimney 137. The chimney cap 133 prevents the liquid stream from entering the chimney 137. The vapor stream exits the chimney assembly 135 via the chimney top opening 138.

After falling to the bottom of the lower section 106, the liquid stream exits the distillation tower 104, 204 through the liquid outlet 160. The liquid outlet 160 is within the lower section 106 (FIGS. 1-4). The liquid outlet 160 may be located at the bottom of the lower section 106.

After exiting through the liquid outlet 160, the feed stream may travel via line 28 to the first reboiler 112. The feed stream may be heated by the first reboiler 112 and vapor may then re-enter the lower section 106 through line 30. Unvaporized liquid may continue out of the distillation process via line 24.

The systems may include an expander device 114 (FIGS. 1-4). After entering line 24, the heated liquid stream may be expanded in the expander device 114. The expander device 114 may be any suitable device, such as a valve. The valve 114 may be any suitable valve, such as a J-T valve.

The systems may include a heat exchanger 116 (FIGS. 1-4). The liquid stream heated by the first reboiler 112 may be cooled or heated by the heat exchanger 116. The heat exchanger 116 may be a direct heat exchanger or an indirect heat exchanger. The heat exchanger 116 may comprise any suitable heat exchanger.

The vapor stream in the lower section 106 rises from the lower section 106 to the middle controlled freeze zone section 108. The middle controlled freeze zone section 108 is constructed and arranged to separate the feed stream 10 introduced into the middle controlled freeze zone section, or into the top of lower section 106, into a solid and a vapor stream. The solid may be comprised more of contaminants than of methane. The vapor stream (i.e., methane-enriched vapor stream) may comprise more methane than contaminants.

The middle controlled freeze zone section 108 includes a lower section 40 and an upper section 39. The lower section 40 is below the upper section 39. The lower section 40 directly abuts the upper section 39. The lower section 40 is primarily but not exclusively a heating section of the middle controlled freeze zone section 108. The upper section 39 is primarily but not exclusively a cooling section of the middle controlled freeze zone section 108. The temperature and pressure of the upper section 39 are chosen so that the solid can form in the middle controlled freeze zone section 108.

The middle controlled freeze zone section 108 may comprise a melt tray assembly 139 that is maintained in the middle controlled freeze zone section 108 (FIGS. 1-4). The melt tray assembly 139 is within the lower section 40 of the middle controlled freeze zone section 108. The melt tray assembly 139 is not within the upper section 39 of the middle controlled freeze zone section 108.

The melt tray assembly 139 is constructed and arranged to melt solids formed in the middle controlled freeze zone section 108. When the warm vapor stream rises from the lower section 106 to the middle controlled freeze zone section 108, the vapor stream immediately encounters the melt tray assembly 139 and supplies heat to melt the solids. The melt tray assembly 139 may comprise at least one of a melt tray 118, a bubble cap 132, a liquid 130 and heat mechanism(s) 134.

The melt tray 118 may collect a liquid and/or slurry mix. The melt tray 118 divides at least a portion of the middle controlled freeze zone section 108 from the lower section 106. The melt tray 118 is at the bottom 45 of the middle controlled freeze zone section 108.

One or more bubble caps 132 may act as a channel for the vapor stream rising from the lower section 106 to the middle controlled freeze zone section 108. The bubble cap 132 may provide a path for the vapor stream up the riser 140 and then down and around the riser 140 to the melt tray 118. The riser 140 is covered by a cap 141. The cap 141 prevents the liquid 130 from travelling into the riser and it also helps prevent solids from travelling into the riser 140. The vapor stream's traversal through the bubble cap 132 allows the vapor stream to transfer heat to the liquid 130 within the melt tray assembly 139.

One or more heat mechanisms 134 may further heat up the liquid 130 to facilitate melting of the solids into a liquid and/or slurry mix. The heat mechanism(s) 134 may be located anywhere within the melt tray assembly 139. For example, as shown in FIGS. 1-4, a heat mechanism 134 may be located around bubble caps 132. The heat mechanism 134 may be any suitable mechanism, such as a heat coil. The heat source of the heat mechanism 134 may be any suitable heat source.

The liquid 130 in the melt tray assembly is heated by the vapor stream. The liquid 130 may also be heated by the one or more heat mechanisms 134. The liquid 130 helps melt the solids formed in the middle controlled freeze zone section 108 into a liquid and/or slurry mix. Specifically, the heat transferred by the vapor stream heats up the liquid, thereby enabling the heat to melt the solids. The liquid 130 is at a level sufficient to melt the solids.

The middle controlled freeze zone section 108 may also comprise a spray assembly 129. The spray assembly 129 cools the vapor stream that rises from the lower section 40. The spray assembly 129 sprays liquid, which is cooler than the vapor stream, on the vapor stream to cool the vapor stream. The spray assembly 129 is within the upper section 39. The spray assembly 129 is not within the lower section 40. The spray assembly 129 is above the melt tray assembly 139. In other words, the melt tray assembly 139 is below the spray assembly 129.

The spray assembly 129 includes one or more spray nozzles 120 (FIGS. 1-4). Each spray nozzle 120 sprays liquid on the vapor stream. The spray assembly 129 may also include a spray pump 128 (FIGS. 1-4) that pumps the liquid. Instead of a spray pump 128, gravity may induce flow in the liquid.

The liquid sprayed by the spray assembly 129 contacts the vapor stream at a temperature and pressure at which solids form. Solids, containing mainly contaminants, form when the sprayed liquid contacts the vapor stream, 302 (FIG. 6). The solids fall toward the melt tray assembly 139.

The temperature in the middle controlled freeze zone section 108 cools down as the vapor stream travels from the bottom of the middle controlled freeze zone section 108 to the top of the middle controlled freeze zone section 108. The methane in the vapor stream rises from the middle controlled freeze zone section 108 to the upper section 110. Some contaminants may remain in the methane and also rise. The contaminants in the vapor stream tend to condense or solidify with the colder temperatures and fall to the bottom of the middle controlled freeze zone section 108.

The solids form the liquid and/or slurry mix when in the liquid 130. The liquid and/or slurry mix flows from the middle controlled freeze zone section 108 to the lower distillation section 106. The liquid and/or slurry mix flows from the bottom of the middle controlled freeze zone section 108 to the top of the lower section 106 via a line 22 (FIGS. 1-4). The line 22 may be an exterior line. The line 22 may extend from the distillation tower 104, 204. The line 22 may extend from the middle controlled freeze zone section 108. The line may extend to the lower section 106. The line 22 may extend from an outer surface of the distillation tower 104, 204.

The vapor stream that rises in the middle controlled freeze zone section 108 and does not form solids or otherwise fall to the bottom of the middle controlled freeze zone section 108, rises to the upper section 110. The upper section 110 operates at a temperature and pressure and contaminant concentration at which no solid forms. The upper section 110 is constructed and arranged to cool the vapor stream to separate the methane from the contaminants. Reflux in the upper section 110 cools the vapor stream. The reflux is introduced into the upper section 110 via line 18. Line 18 may extend to the upper section 110. Line 18 may extend from an outer surface of the distillation tower 104, 204.

After contacting the reflux in the upper section 110, the feed stream forms a vapor stream and a liquid stream. The vapor stream mainly comprises methane. The liquid stream comprises relatively more contaminants. The vapor stream rises in the upper section 110 and the liquid falls to a bottom of the upper section 110.

To facilitate separation of the methane from the contaminants when the stream contacts the reflux, the upper section 110 may include one or more mass transfer devices 176. Each mass transfer device 176 helps separate the methane from the contaminants. Each mass transfer device 176 may comprise any suitable separation device, such as a tray with perforations, or a section of random or structured packing to facilitate contact of the vapor and liquid phases.

After rising, the vapor stream may exit the distillation tower 104, 204 through line 14. The line 14 may emanate from an upper part of the upper section 110. The line 14 may extend from an outer surface of the upper section 110.

From line 14, the vapor stream may enter a condenser 122. The condenser 122 cools the vapor stream to form a cooled stream. The condenser 122 at least partially condenses the stream.

After exiting the condenser 122, the cooled stream may enter a separator 124. The separator 124 separates the vapor stream into liquid and vapor streams. The separator may be any suitable separator that can separate a stream into liquid and vapor streams, such as a reflux drum.

Once separated, the vapor stream may exit the separator 124 as sales product. The sales product may travel through line 16 for subsequent sale to a pipeline and/or condensation to be liquefied natural gas.

Once separated, the liquid stream may return to the upper section 110 through line 18 as the reflux. The reflux may travel to the upper section 110 via any suitable mechanism, such as a reflux pump 150 (FIGS. 1 and 3) or gravity (FIGS. 2 and 4).

The liquid stream (i.e., freezing zone liquid stream) that falls to the bottom of the upper section 110 collects at the bottom of the upper section 110. The liquid may collect on tray 183 (FIGS. 1 and 3) or at the bottommost portion of the upper section 110 (FIGS. 2 and 4). The collected liquid may exit the distillation tower 104, 204 through line 20 (FIGS. 1 and 3) or outlet 260 (FIGS. 2 and 4). The line 20 may emanate from the upper section 110. The line 20 may emanate from a bottom end of the upper section 110. The line 20 may extend from an outer surface of the upper section 110.

The line 20 and/or outlet 260 connect to a line 41. The line 41 leads to the spray assembly 129 in the middle controlled freeze zone section 108. The line 41 emanates from the holding vessel 126. The line 41 may extend to an outer surface of the middle controlled freeze zone section 110.

The line 20 and/or outlet 260 may directly or indirectly (FIGS. 1-4) connect to the line 41. When the line 20 and/or outlet 260 directly connect to the line 41, the liquid spray may be pumped to the spray nozzle(s) 120 via any suitable mechanism, such as the spray pump 128 or gravity. When the line 20 and/or outlet 260 indirectly connect to the line 41, the lines 20, 41 and/or outlet 260 and line 41 may directly connect to a holding vessel 126 (FIGS. 1 and 3). The holding vessel 126 may house at least some of the liquid spray before it is sprayed by the nozzle(s). The liquid spray may be pumped from the holding vessel 126 to the spray nozzle(s) 120 via any suitable mechanism, such as the spray pump 128 (FIGS. 1-4) or gravity. The holding vessel 126 may be needed when there is not a sufficient amount of liquid stream at the bottom of the upper section 110 to feed the spray nozzles 120.

It is important to note that the steps depicted in FIG. 6 provided for illustrative purposes only and a particular step may not be required to perform the inventive methodology. The claims, and only the claims, define the inventive system and methodology.

Disclosed aspects may be used in hydrocarbon management activities. As used herein, “hydrocarbon management” or “managing hydrocarbons” includes hydrocarbon extraction, hydrocarbon production, hydrocarbon exploration, identifying potential hydrocarbon resources, identifying well locations, determining well injection and/or extraction rates, identifying reservoir connectivity, acquiring, disposing of and/or abandoning hydrocarbon resources, reviewing prior hydrocarbon management decisions, and any other hydrocarbon-related acts or activities. The term “hydrocarbon management” is also used for the injection or storage of hydrocarbons or CO₂, for example the sequestration of CO₂, such as reservoir evaluation, development planning, and reservoir management. The disclosed methodologies and techniques may be used to produce hydrocarbons in a feed stream extracted from, for example, a subsurface region. The feed stream extracted may be processed in the distillation tower 104, 204 and separated into hydrocarbons and contaminants. The separated hydrocarbons exit the middle controlled freeze zone section 108 or the upper section 110 of the distillation tower. Some or all of the hydrocarbons that exit are produced, 307 (FIG. 6). Hydrocarbon extraction may be conducted to remove the feed stream from for example, the subsurface region, which may be accomplished by drilling a well using oil well drilling equipment. The equipment and techniques used to drill a well and/or extract the hydrocarbons are well known by those skilled in the relevant art. Other hydrocarbon extraction activities and, more generally, other hydrocarbon management activities, may be performed according to known principles.

As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numeral ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described are considered to be within the scope of the disclosure.

It should be understood that numerous changes, modifications, and alternatives to the preceding disclosure can be made without departing from the scope of the disclosure. The preceding description, therefore, is not meant to limit the scope of the disclosure. Rather, the scope of the disclosure is to be determined only by the appended claims and their equivalents. It is also contemplated that structures and features in the present examples can be altered, rearranged, substituted, deleted, duplicated, combined, or added to each other.

The articles “the”, “a” and “an” are not necessarily limited to mean only one, but rather are inclusive and open ended so as to include, optionally, multiple such elements. 

What is claimed is:
 1. A method of dehydrating a feed stream processed in a distillation tower, the method comprising: (a) introducing a feed stream comprising a first contaminant stream into a distillation tower; (b) forming a solid from the feed stream in a controlled freeze zone section of the distillation tower; (c) feeding a second contaminant stream into the feed stream outside of the distillation tower; and (d) removing water from the feed stream with the second contaminant stream by feeding the second contaminant stream.
 2. The method of claim 1, wherein the second contaminant stream is at least a portion of the first contaminant stream.
 3. The method of claim 1, wherein the first contaminant stream comprises a different type of contaminant from the second contaminant stream.
 4. The method of claim 1, wherein at least one of the first contaminant stream and the second contaminant stream comprises carbon dioxide.
 5. The method of claim 1, wherein removing the water comprises processing the feed stream in one of a glycol-based unit and a molecular sieve unit.
 6. The method of claim 1, wherein feeding the second contaminant stream comprises at least one of (i) transporting the second contaminant stream from the distillation tower to the feed stream and (ii) transporting the second contaminant stream from a second contaminant storage tank to the feed stream.
 7. The method of claim 6, wherein the second contaminant storage tank is outside of the distillation tower.
 8. The method of claim 1, wherein feeding the second contaminant stream comprises transporting the second contaminant stream to the feed stream at least one of before the feed stream enters a dehydration unit and before it enters a heat exchanger.
 9. The method of claim 1, wherein a total amount of contaminant comprises the first contaminant stream and the second contaminant stream, and wherein the method further comprises increasing the total amount of contaminant in the feed stream to between about 25 to 35 percent.
 10. A method of producing hydrocarbons, the method comprising: (a) introducing a feed stream comprising a first contaminant stream and a hydrocarbon into a distillation tower; (b) forming a solid from the feed stream in a controlled freeze zone section of the distillation tower; (c) feeding a second contaminant stream into the feed stream outside of the distillation tower; (d) removing water from the feed stream with a second contaminant stream by feeding the second contaminant stream; and (e) producing the hydrocarbon from the distillation tower after forming the solid.
 11. The method of claim 10, wherein the second contaminant stream is at least a portion of the first contaminant stream.
 12. The method of claim 10, wherein the first contaminant stream comprises a different type of contaminant from the second contaminant stream.
 13. The method of claim 10, wherein at least one of the first contaminant stream and the second contaminant stream comprises carbon dioxide.
 14. The method of claim 10, wherein removing the water comprises processing the feed stream in one of a glycol-based unit and a molecular sieve.
 15. The method of claim 10, wherein feeding the second contaminant stream comprises at least one of (i) transporting the second contaminant stream from the distillation tower to the feed stream and (ii) transporting the second contaminant stream from a second contaminant storage tank to the feed stream.
 16. The method of claim 15, wherein the second contaminant storage tank is outside of the distillation tower.
 17. The method of claim 10, wherein feeding the second contaminant stream comprises transporting the second contaminant stream to the feed stream at least one of before the feed stream enters a dehydration unit and a heat exchanger.
 18. The method of claim 10, wherein a total amount of contaminant comprises the first contaminant stream and the second contaminant stream, and wherein the method further comprises increasing the total amount of contaminant in the feed stream to between about 25 to 35 percent.
 19. A system of dehydrating a feed stream processed in a distillation tower, the system comprising: a dehydration unit that dehydrates a feed stream comprising a first contaminant stream; a feed stream inlet channel extending from the dehydration unit; a distillation tower comprising a controlled freeze zone section constructed and arranged to form a solid from the feed stream; and at least one of: (a) a second contaminant storage tank holding a second contaminant stream and connected to the feed stream inlet channel, and (b) a distillation tower outlet channel extending from the distillation tower to the feed stream inlet channel and constructed and arranged to transport the second contaminant stream, wherein the feed stream inlet channel extends to the distillation tower and is constructed and arranged to transport the first contaminant stream and the second contaminant stream.
 20. The system of claim 19, wherein the dehydration unit comprises one of a glycol-based unit and a molecular sieve.
 21. The system of claim 19, wherein the second contaminant stream is at least a portion of the first contaminant stream.
 22. The system of claim 19, wherein the first contaminant stream is one of a same type and a different type of contaminant from the second contaminant stream.
 23. The system of claim 19, wherein at least one of the first contaminant stream and the second contaminant stream comprises carbon dioxide.
 24. The system of claim 19, wherein the distillation outlet channel connects to the feed stream inlet channel before the dehydration unit and the distillation tower.
 25. The system of claim 19, wherein the distillation outlet channel connects to the feed stream inlet channel between the dehydration unit and a heat exchanger.
 26. The system of claim 19, further comprising a storage tank channel that extends from the second contaminant storage tank to the feed stream inlet channel before the dehydration unit and the distillation tower.
 27. The system of claim 19, further comprising a storage tank channel that extends from the second contaminant storage tank to the feed stream inlet channel between the dehydration unit and a heat exchanger. 